Compositions, zinc electrodes, batteries and their methods of manufacture

ABSTRACT

A composition, method of its preparation, and zinc electrodes comprising the composition as the active mass, for use in rechargeable electrochemical cells with enhanced cycle life is described. The electrode active mass comprises a source of electrochemically active zinc and at least one fatty acid or a salt, ester or derivative thereof, or an alkyl sulfonic acid or a salt ester or derivative thereof. The zinc electrode is assumed to exhibit low shape change and decreased dendrite formation compared to known zinc electrodes, resulting in electrochemical cells which have improved capacity retention over a number of charge/discharge cycles.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of PCT Application No.PCT/NZ02/00036, filed Mar. 15, 2002, which claimed priority from NewZealand Patent Application No. 510554 filed Mar. 15, 2001, thedisclosures of both of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to compositions, zinc electrodes,batteries and their methods of manufacture. In particular, it relates torechargeable zinc cells incorporating such electrodes as anodes.

BACKGROUND OF THE INVENTION

The potential utilization of zinc electrodes in rechargeable alkalineelectrochemical cells, in particular nickel-zinc batteries, has longbeen realised [1]. Nickel-zinc batteries have been demonstrated to havegood performance criteria, including:

-   i) energy density of 55-85 wh/kg,-   ii) power density of 140-200 W/kg,-   iii) open circuit potential of 1.75 V, and-   iv) a self discharge rate of <0.8%/day.

However, a number of problems associated with the zinc electrode existthat prevent such batteries being charged and discharged for sufficientcycles to be of practical use. These problems arise from the propensityof the zinc electrode to exhibit changes in shape, commonly referred toas ‘shape change’, upon discharge/charge cycling. Shape change is causedby the solubility of the zinc electrode discharge products in thealkaline electrolyte as the species zincate, Zn(OH)₄ ²⁻. Eventually,solid zinc hydroxide does precipitate out of solution onto the electrodesurface, but this may occur at locations remote from the dischargereaction site. Consequently, upon recharging, the zinc electrode becomesthicker in some locations and thinner in others. This may occur on agross scale, where electrodes swell or fracture respectively, or may belimited to decreasing the active surface area of zinc metal crystalliteson the surface of the zinc electrodes.

In addition to shape change, the phenomenon of zinc dendrite growth alsotakes place. Dendrite growth occurs when redeposition of zinc metal onrecharge takes place at a collection of points on the electrode surface,rather than as an even distribution across the entire surface. Thesource of zinc material for reduction is not the precipitated zinchydroxide, but the dissolved zinc in solution. Narrow needles ordendrites of zinc metal grow from the electrode surface and eventuallyform an internal electrical short to the nickel electrode causing thebattery to fail.

A number of different approaches have been attempted to negate orprevent the effects of shape change and dendrite growth. These are, forthe most part, focused on decreasing the solubility of the zincelectrode discharge products in the electrolyte. This has been attemptedby modifications to the zinc electrode active mass, electrolyte andseparators, the latter to prevent growth of dendrites through theseparator which otherwise would short the cell. These modifications aresummarised in Tables 1-3, below. TABLE 1 Additives to the active massshowing improved performance Additive Refs. Acetylene black  [2] Ca(OH)₂ [3] CdO  [4] Organic polymers  [5] Zn alloys [6-8] SnO or Sn(OH)₂, PbOor Pb(OH)₂  [9] HgO + organic binder [10] Ba(OH)₂ or Sr(OH)₂ [11]

TABLE 2 Additives to the electrolyte showing Improved performanceAdditive Refs. ZnO, (NH₄)₂CS [12] Carbonate salts [13] Et₄NBr [14] Alkylethers of poly(propyleneglycol) [15] Mixtures of fatty acids salts,fatty acid esters, [16] aliphatic alcohols & hydrocarbons Fluoride saltsand hydroxides [17, 18]

TABLE 3 Additives to the separator showing improved performance AdditiveRefs. Carboxymethylcellulose [19] Sucrose fatty acid esters [20]Sorbitan fatty acid esters [21]

Bocharov et al., USSR SU Patent No. 1 457 760 (1992) [16], disclosed anelectrolyte for a nickel zinc battery containing C₁₀-C₁₆ fatty acids asa mixture together with a number of long alkyl chain esters, alcoholsand hydrocarbons that exhibited improved performance.

Okabe et al. in two patents described the use of fatty acid esters ofsucrose, Jpn. Patent JP No. 07 161 376 [20], and sorbitan, Jpn. PatentJP No. 07 161 375 [21], coated on nickel zinc battery separators toinhibit growth of dendrites through this component. It is most probablethat in this strongly alkaline electrolyte, hydrolysis of the fatty acidesters occurs to yield the free fatty acids in the electrolyte.

Whilst these modifications were shown to improve the performance ofnickel-zinc batteries at low charge and discharge rates, there is stilla need for a rechargeable nickel-zinc battery with demonstrably lowshape change together with the absence of dendrite growth at high chargeand discharge rates.

It is therefore an object of the present invention to provide arechargeable zinc electrode and rechargeable zinc cell which go some waytowards achieving this desideratum, or to at least provide the publicwith a useful choice.

SUMMARY OF THE INVENTION

Accordingly, in a first aspect the present invention provides an activecomposition for use in preparing a zinc electrode including:

-   (a) a source of zinc capable of existing in an oxidised and a    reduced state; and-   (b) at least one compound selected from the group consisting of    C₆-C₃₀ fatty acids, salts, esters and other derivatives thereof, and    C₆-C₃₀ alkyl sulfonic acids, salts, esters and other derivatives    thereof.

In a second aspect the present invention provides a method of preparinga composition for use in preparing a zinc electrode including the stepsof:

-   -   Preparing a first precipitate of zinc hydroxide;    -   Mixing a solution of an alkali salt of either a C₆-C₃₀ fatty        acid or a C₆-C₃₀ alkyl sulfonic acid with a suspension of the        first precipitate; and    -   Adding a solution of a salt of a mineral acid to the mix to        provide the composition as a second precipitate;    -   wherein the composition is a mixture of zinc oxide and/or zinc        hydroxide, and an insoluble salt of either a C₆-C₃₀ fatty acid        or a C₆-C₃₀ alkyl sulfonic acid.

In a third aspect the present invention provides a composition preparedby the method of the second aspect of the invention.

In this specification the term “C₆-C₃₀ fatty acids” includes saturated,unsaturated and polyunsaturated, naturally occurring and synthetic,fatty acids of 6 to 30 carbon atoms in length. It also includes suchfatty acids which may additionally be substituted with one or moresubstituents, and/or which incorporate aromatic carbocyclic orheterocyclic rings, fused aromatic rings or polycyclic systems includingaromatic rings. The aromatic rings may themselves be optionallysubstituted. Suitable substituents include halogen, amino, nitro, alkyl,alkoxy, carboxyl, hydroxy, amide or ester groups.

The term “C₆-C₃₀ alkyl sulfonic acids” includes alkyl sulfonic acids 6to 30 carbon atoms in length. It also includes such alkyl sulfonic acidswhich may additionally be substituted with one or more substituents,and/or incorporate aromatic carbocyclic or heterocyclic rings, fusedaromatic rings or polycyclic systems including aromatic rings. Thearomatic rings may themselves be optionally substituted. Suitablesubstituents include those defined above under the term “C₆-C₃₀” fattyacids.

The term “derivative” when used in relation to “C₆-C₃₀ fatty acids” or“C₆-C₃₀ alkyl sulfonic acids” means any derivative, such as an ester,which is capable of being hydrolysed under alkaline conditions to yieldthe free fatty acid or alkyl sulfonic acid salt.

While component (b) may be a single compound selected from the groupconsisting of C₆-C₃₀ fatty acids, salts, esters and other derivativesthereof, and C₆-C₃₀ alkyl sulfonic acids, salts, esters and otherderivatives thereof, embodiments in which component (b) includes two ormore of these compounds are also contemplated.

Preferably, component (b) comprises a C₆-C₃₀ fatty acid, salt, or esterthereof.

More preferably, the fatty acid, salt or ester thereof is a naturallyoccurring C₁₂-C₂₂, still more preferably C₁₆-C₂₀, fatty acid, salt orester.

Yet more preferably, the fatty acid, salt or ester thereof is stearicacid, or a salt or ester thereof.

Preferably, the active composition comprises components (a) and (b) inadmixture.

In preferred embodiments, the active composition comprises a mixture ofa salt of stearic acid and one or both of zinc oxide and zinc hydroxide.

In one preferred embodiment, the active composition comprises zincstearate and one or both of zinc oxide and zinc hydroxide. In thisembodiment, preferably the zinc stearate:zinc oxide/hydroxide molarratio is in the range 0.0001:1 to 0.5:1, more preferably 0.05:1 to0.4:1, and still more preferably from 0.075:1 to 0.25:1.

In another preferred embodiment, the active composition comprisescalcium stearate and one or both of zinc oxide and zinc hydroxide. Inthis embodiment, preferably the calcium stearate:zinc oxide/hydroxidemolar ratio is in the range of 0.0001:1 to 0.2:1, more preferably 0.01:1to 0.2:1, and still more preferably 0.03:1 to 0.15:1.

In other preferred embodiments, the active composition comprisesmagnesium stearate, strontium stearate or barium stearate and one orboth of zinc oxide and zinc hydroxide. In this embodiment, preferablythe magnesium, strontium or barium stearate:zinc oxide/hydroxide molarratio is in the range 0.0001:1 to 0.2:1, more preferably 0.01:1 to0.2:1, and still more preferably 0.03:1 to 0.15:1.

In yet another preferred embodiment, the active composition comprisesiron (II) stearate, iron (III) stearate or aluminium stearate and one orboth of zinc oxide and zinc hydroxide. In this embodiment, preferablythe iron (II), iron (III) or aluminium stearate:zinc oxide/hydroxidemolar ratio is in the range 0.0001:1 to 0.2:1, more preferably 0.01:1 to0.2:1, and still more preferably 0.05:1 to 0.15:1.

Optionally, the active composition also includes graphite powder. Whenincluded, the graphite powder preferably comprises 0.1 to 60%, morepreferably 10 to 45%, and still more preferably 15 to 35%, by weight ofthe active composition.

Optionally, the active composition also includes a lead (II) salt, forexample Pb(NO₃)₂. When the lead (II) salt is included, preferably thelead (II):zinc molar ratio is in the range 0.0005:1 to 0.1:1.

Optionally, the active composition also includes a copper (II) salt, forexample Cu(NO₃)₂. When the copper (II) salt is included, preferably thecopper (II):zinc molar ratio is in the range 0.0005:1 to 0.1:1.

In a fourth aspect the present invention provides an electrodecomprising a composition of the first or third aspect of the invention.

Preferably, the zinc electrode comprises the active composition appliedto a current collector.

In a fifth aspect the present invention provides a composition preparedfrom an electrode of the fourth aspect of the invention wherein theelectrode has been charged.

In a sixth aspect the present invention provides a method of preparingan electrode including the steps of:

-   -   Mixing solid alkali metal hydroxide with a composition of the        first or third aspect of the invention;    -   Applying the mix on to a current collector; and    -   Forming the electrode.

In a seventh aspect the present invention provides a cell comprising atleast one electrode of the fourth aspect of the invention.

Preferably the cell comprises a non-conventional separator wherein theseparator is porous. More preferably the separator is a woven cloth.Most preferably the separator is woven nylon cloth.

In one embodiment the cell excludes the use of a conventional separator.

Preferably the cell comprises an electrolyte saturated with zinc oxide.More preferably the electrolyte is super-saturated with zinc oxide.

Preferably the cell is a rechargeable cell.

Preferably, the zinc electrode is such that the cell, after at least 350charge/discharge cycles, at charge and discharge rates such that chargeand discharge of the battery are complete within 2-2.5 hours and 1-1.5hours respectively, maintains at least 55% of the initial capacity ofthe cell.

Preferably, the zinc electrode is such that the cell, after at least1134 charge/discharge cycles, at charge and discharge rates such thatcharge and discharge of the battery are complete within 2 hours and 1.7hours respectively, maintains at least 80% of the initial capacity ofthe cell.

While the invention is broadly as defined above, it is not limitedthereto and also includes embodiments of which the following descriptionprovides examples.

DESCRIPTION OF THE DRAWINGS

The present invention will now be described in more detail and withreference to the accompanying drawings, in which:

FIG. 1 is a schematic diagram of a rechargeable zinc cell of the presentinvention;

FIG. 2 shows the battery capacity of a rechargeable zinc cell of theinvention, as a function of cycle number for discharge/charge cycling.Crosshairs indicate 55% theoretical battery capacity at 355 cycles. Thedashed line shows the initial maximum capacity of 83% at 49 cycles(ignoring brief excursions above this value at cycles 37 and 98-102);and

FIG. 3 shows the battery capacity of another rechargeable zinc cell ofthe invention, as a function of cycle number for discharge/chargecycling. The dashed line shows 80% of the theoretical capacity. Themeasured discharge capacity remains above this 80% capacity for inexcess of 1134 charge/discharge cycles.

DETAILED DESCRIPTION OF THE INVENTION

As defined above, the present invention relates to new zinc electrodes,and to rechargeable zinc cells containing such electrodes.

The applicants have surprisingly found that a significant improvement inthe performance of zinc cells has been achieved. This improvement isattributed to a lowering of the shape change in a zinc electrode and theamount of dendrite growth can be achieved by incorporating a fatty acid,or a salt, ester other derivative thereof into the active composition ofthe zinc electrode.

Additional advantages accrue from a lowering of the amount of dendritegrowth. These advantages include the ability to construct certain cells,e.g. Ni—Zn cells, in which the use of a conventional separator is notessential.

“Conventional separators” for use in alkaline cells are a permeable orsemipermeable membrane that is located between the electrodes. Theseparator provides a physical barrier to dendrite growth. However, theseparator must also be permeable to ions in the electrolyte.

Conventional separators such as Celgard™ are a membrane ofpolypropylene. Cellulose-based membranes have also been used asseparators. These include cellophane and sausage casing material.

The use of conventional separators such as Celgard™ is problematic. Theproduct is relatively costly. Cellulose-based separators are unstable inalkaline electrolytes.

Further disadvantages of conventional separators include the thicknessof the membrane differing between dry and wet states. This may result inthe cell rupturing as the wetted membrane thickens.

Conventional separators also place a limit on the rate of ion flowbetween the separated electrolyte containing compartments. Thislimitation has a bearing on the maximum current and discharge rateobtainable from alkaline cells constructed using a conventionalseparator.

It has been demonstrated by the inventors that a porous separator suchas woven nylon cloth may be used in the construction of cells comprisingthe zinc electrodes of the invention.

It is contemplated that in the construction of cells according to theinvention the requirement for a separator could be eliminatedaltogether. However, it is recognised that in the manufacture of cellsit may often be desirable to use a separator such as woven nylon cloth,if only to act as a spacer to ensure physical separation of theelectrodes.

Materials suitable for use as a separator (or spacer) as contemplated bythe inventors include any material that is physically stable (andpreferably chemically stable) in the electrolyte under the conditions ofuse of the cell for the lifetime of the cell.

The material of the separator is of a porous form and may be eitherwoven or unwoven e.g. matted, sintered or fused fibres. Suitablematerials include, but are not limited to, polyamides (such as nylon)and polyalkenes (such as polyethylene and polypropylene).

In a preferred embodiment a cell constructed using a non-conventionalseparator as described above and comprising a zinc electrode may providea cell with high discharge rates.

In particular, in preferred embodiments of the invention the activezinc-containing material of the zinc electrode, after at least 350charge/discharge cycles, at high charge discharge rates has been foundto maintain sufficient electroactive surface area on the electrode toprovide at least 55% of the initial capacity of the electrode.

In other preferred embodiments of the invention the activezinc-containing material of the zinc electrode, after at least 1134charge/discharge cycles at high charge/discharge rates, has been foundto maintain sufficient electroactive surface area on the electrode toprovide at least 80% of the initial capacity of the electrode.

Furthermore, there is no discernible relocation of the zinc activecomposition within the cell, either on the separators or the walls ofthe container.

The rechargeable zinc electrodes of the invention therefore contain anactive composition comprising at least:

-   (a) a source of zinc capable of being repeatedly cycled between an    oxidised and a reduced state; and-   (c) at least one compound selected from the group consisting of    C₆-C₃₀ fatty acids, salts, esters and other derivatives thereof, and    C₆-C₃₀ alkyl sulfonic acids, salts, esters and other derivatives    thereof (as defined above).

In preferred embodiments of the invention, the component (b) of theactive composition comprises a naturally occurring C₁₂-C₂₂ fatty acid,or a salt or ester thereof. It is preferred that component (b) is aC₁₆-C₂₀ fatty acid, salt or ester, with a particularly preferred fattyacid being stearic acid, or a salt or ester thereof.

It will be appreciated that the source of zinc can be anyelectrochemically active form of zinc capable of being repeatedly cycledbetween an oxidised and reduced state (containing zinc metal in thecharged state). It is however generally preferred that the source ofzinc be provided by a zinc salt (such as zinc sulphate or zinc nitrate),or by zinc oxide and/or hydroxide. In these embodiments of theinvention, it is preferred that the active composition comprises amixture of the source of zinc and the fatty acid, salt or ester.

The active composition may be formed as an intimate mixture, byprecipitation of a zinc salt of a fatty acid and zinc hydroxide by rapidmixing of an alkaline mixture of the fatty acid, and the zinc salt (forexample zinc sulphate or zinc nitrate). Species such as the salt zincmono stearate monohydroxide may also form in this preparation andfurther enhance the battery performance. In alternative embodiments, theactive composition may be prepared simply by mixing the two components(a) and (b) as solid materials after separate preparation.

In further alternative embodiments, the active composition may be formedby adding other salts of a fatty acid, such as a potassium, sodium orlithium salt, to zinc hydroxide or zinc oxide, so that a zinc fatty acidsalt forms on subsequent charge/discharge cycling.

The active composition may also be formed as an intimate mixture by theprecipitation of a calcium salt of a fatty acid and zinc hydroxide byrapid mixing of an alkaline mixture of the fatty acid, a calcium salt(for example calcium sulphate or calcium nitrate) and a zinc salt.Species such as the salt calcium mono stearate monohydroxide may alsoform in this preparation and further enhance the battery performance.

In alternative embodiments, the active composition may be formed byadding other salts of a fatty acid, such as a potassium, sodium orlithium salt, to zinc hydroxide or zinc oxide, together with a calciumsalt, so that a calcium fatty acid salt forms on subsequentcharge/discharge cycling.

In further alternative embodiments, the active composition may be formedby adding other salts of a fatty acid, such as a potassium, sodium orlithium salt, to zinc hydroxide or zinc oxide, together with amagnesium, strontium or barium salt, so that a magnesium, strontium orbarium fatty acid salt forms on subsequent charge/discharge cycling.

In one preferred embodiment, the active composition comprises a mixtureof zinc oxide and/or zinc hydroxide with zinc stearate. Such a mixturemay conveniently be prepared by adding an alkali to stearic acid, andthen adding zinc sulfate or zinc nitrate.

In another preferred embodiment, the active composition comprises amixture of zinc oxide and/or zinc hydroxide with calcium stearate. Sucha mixture can conveniently be prepared by precipitation from an alkalinestearate solution containing a zinc salt and a calcium (II) salt such ascalcium nitrate.

In further preferred embodiments, the active composition comprises amixture of zinc oxide and/or zinc hydroxide with magnesium stearate,strontium stearate or barium stearate. Such a mixture may convenientlybe prepared by precipitation from an alkaline stearate solutioncontaining a zinc salt and a magnesium (II), strontium (II) or barium(II) salt.

In other preferred embodiments, the active composition comprises amixture of zinc oxide and/or zinc hydroxide with iron (II) stearate,iron (III) stearate or aluminium stearate. Such a mixture mayconveniently be prepared by precipitation from an alkaline stearatesolution containing a zinc salt and an iron (II), iron (III) oraluminium (III) salt.

In further preferred embodiments, the active composition comprises amixture of zinc oxide and/or zinc hydroxide with lead stearate, tinstearate or cadmium stearate. Such a mixture may conveniently beprepared by precipitation from an alkaline stearate solution containinga zinc salt and a lead, tin or cadmium salt.

In still further embodiments, an active composition may be prepared bypasting the zinc source and a source of calcium, magnesium, strontium,barium, iron (II), iron (III), aluminium, lead, tin or cadmium onto asuitable current collector and then spraying, dipping or coating with afatty acid ester solution, solid or melt. The active composition mayalso be prepared by pressing together sintered zinc powder with a fattyacid ester together with a source of calcium, magnesium, strontium,barium, iron (II), iron (III), aluminium, lead, tin or cadmium to forman anode.

In addition to the source of zinc and the fatty acid or salt, ester orother derivative thereof or the alkyl sulfonic acid or salt, ester orother derivative thereof, the active composition of the zinc electrodemay optionally include lead (II) salts, for example Pb(NO₃)₂. When lead(II) salts are included, preferably the lead (II):zinc molar ratio is inthe range 0.0005:1 to 0.1:1. The addition of lead salts may decrease therate of hydrogen evolution at the anode during recharge.

In addition to the source of zinc and the fatty acid or salt, ester orother derivative thereof or the alkyl sulfonic acid or salt, ester orother derivative thereof, the active composition of the zinc electrodemay optionally include copper (II) salts, for example Cu(NO₃)₂. Whencopper (II) salts are included, preferably the copper (II):zinc molarratio is in the range 0.0005:1 to 0.1:1.

Optionally, the active composition also includes graphite powder. Whenincluded, the graphite powder preferably comprises 0.1 to 60%, morepreferably 10 to 45%, and still more preferably 15 to 35%, by weight ofthe active composition. The addition of graphite may decrease theelectrical resistance of the active composition.

The zinc electrodes of the invention will also normally include acurrent collector. Thus, the electrodes may be prepared by pasting theactive composition onto a suitable current collector, for examplegraphite cloth, slotted copper foil or woven brass mesh. Alternatively,the active mass could be spread on a suitable support andelectrochemically or otherwise reduced to give a network of zinc metalas the current collector. Advantageously solid alkali metal hydroxide(base), such as potassium hydroxide, is mixed with the activecomposition.

In another aspect, the present invention provides a rechargeable zinccell containing, as anode, a zinc electrode of the invention.Rechargeable zinc cells containing a zinc electrode of the invention caninclude nickel/zinc cells (containing a nickel electrode as NiOOH in thecharged states); zinc/air cells; silver/zinc cells (containing a silverelectrode as silver oxide in the charged state); and manganese/zinccells (containing a manganese electrode as manganese dioxide in thecharged state). The rechargeable zinc cells of the invention may beprepared by incorporating the electrodes with a suitable electrolyte,electrode connectors and separators, using methods well known in theart.

In one embodiment, the electrolyte is an aqueous solution of a suitablebase. Suitable bases include, but are not limited to potassiumhydroxide, sodium hydroxide and lithium hydroxide and mixtures thereof.In a preferred embodiment the electrolyte is an aqueous solution ofpotassium hydroxide.

Preferably the electrolyte is an aqueous solution of 7M potassiumhydroxide (KOH).

In one embodiment, the electrolyte is saturated with zinc oxide. In apreferred embodiment the electrolyte is super-saturated with zinc oxide.

In this context “super-saturated” is intended to mean a stable solutioncontaining a concentration of zinc oxide greater than that obtained byconventional methods. Conventional methods involve the addition of anexcess of zinc oxide to an aqueous solution of concentrated alkali metalhydroxide. These methods typically provide an electrolyte saturated withzinc oxide up to a concentration of about 47 g/L at 27° C.

It is anticipated that a reduction in self-discharge of charged zincelectrodes may be obtained by use of a super-saturated electrolyte.Additional improvements in the performance of the cell would thereby beobtained.

In one embodiment, the electrolyte is saturated with a suitabletetraalkylammonium salt, such as a tetrabutylammonium salt. In apreferred embodiment, the tetraalkylammonium salt is tetrabutylammoniumhydroxide.

In a preferred embodiment the electrolyte is an aqueous solution ofpotassium hydroxide saturated with both zinc oxide andtetrabutylammonium hydroxide.

In one embodiment, the accessibility of the electrolyte to the electrodeactive mass is restricted, for example by enclosing the electrodeassembly in a suitable material which is stable in the electrolytemedium. Suitable materials include a range of inert plastics such aspolyethylene but are not limited thereto.

The rechargeable cells of the invention may be operated in either asealed or unsealed mode. It is preferred that the cell is operated in asealed mode to permit oxygen generated within the cell to react withzinc, to further inhibit the formation of dendrites. If operated in theunsealed mode, it may be preferable to introduce a one-way valve topermit venting of the cell whilst preventing ingress of air to controlthe carbonate level in the cell.

The invention will now be described in more detail with reference to theaccompanying drawings and the following non-limiting examples.

EXAMPLE 1

A cell was constructed of approximately AA size with two zinc electrodesand one nickel electrode as shown in FIG. 1. The electrodes haddimensions 38 mm×70 mm×1 mm. The nickel electrode was sandwiched betweenthe two zinc electrodes and separated with woven nylon separators andthe electrode assembly enclosed in nylon cloth. The electrode assemblywas mounted in a planar manner within a cell container.

The nickel electrode was obtained from an AA-sized nickel cadmiumbattery produced by JJJ Battery Co. Ltd., Jiangmen, Guangdong Province,P. R. China and was used without further modification.

The zinc electrodes were prepared from an active composition containinga zinc stearate:zinc hydroxide molar ratio of 0.163:1 mixed with carbonpowder (30% by weight in the final mixture). The active mass wasprepared as an intimate mixture by two sequential precipitationprocesses. In the first precipitation process, zinc sulfate (0.1 mol)was dissolved in water (400 mL) and the solution heated to 50-60° C.Aqueous sodium hydroxide was prepared as a separate solution (0.2 molsodium hydroxide in 200 mL). Graphite (8.68 g) was dispersed in thesodium hydroxide solution and the sodium hydroxide/graphite suspensionwas added slowly with stirring to the zinc sulfate solution. A graysuspension of intimately mixed zinc hydroxide and graphite particulateswas formed. The pH was adjusted to pH 8-9.

An aqueous potassium stearate solution (500 mL) at 50-60° C. preparedfrom a stoichiometric mixture of stearic acid (0.0326 mol) and potassiumhydroxide (0.0326 mol) was added slowly with stirring to the zinchydroxide-graphite suspension at 50-60° C. The pH of this mixture wasadjusted to 8-9. The mixture was stirred for 5-10 minutes to ensurethorough mixing of potassium stearate with the zinc hydroxide andgraphite particles.

In the second precipitation process, a solution of zinc sulfate (0.0163mol) dissolved in water (100 mL) was added to the mixture of potassiumstearate, zinc hydroxide and graphite. This resulted in immediateprecipitation of zinc stearate and gave the zinc active mass as a grayprecipitate where the zinc stearate, zinc hydroxide and graphite werepresent as an intimate mixture. This final precipitated mixture washeated to 70° C. and stirred for a further 10 minutes. Upon cessation ofstirring, the active mass mixture settled as a uniformly gray materialwith no stratification consistent with a homogenous mass. After coolingto room temperature, this active mass was filtered and washed withwater. The active mass was used immediately without drying.

The active composition was physically supported on the current collectorby inclusion of non-woven polyester cloth. The current collector waswoven graphite cloth electrochemically plated with metallic tin from analkaline sodium stannate solution (2A for 2 min). External electricalcontact was made by crimping nickel foil onto the graphite cloth.

The zinc active mass was pasted onto the current collectors so that eachzinc electrode contained 0.040 mol of zinc hydroxide.

The electrolyte was 7 M KOH saturated with tetrabutylammonium hydroxideand saturated with ZnO.

In the schematic diagram of the cell shown in FIG. 1, the cell includesa battery case 1, negative electrode connector 2, positive electrodeconnector 3, negative plate internal connecting strap 4, negativeelectrode plate 5, positive electrode plate 6 and separators 7.

The cell was cycled through charge and discharge modes. Charging wasmaintained at a current of 200 mA for 2 hours, with the exception ofcycle numbers 31 to 179 where charging was maintained at 200 mA for 2.25hours. Discharge was through a constant load of 4.9 Ω until the cellvoltage dropped to 1 V, indicating full discharge of the cell.

Discharge current was calculated by the cell voltage divided by theconstant resistance load. Discharge capacity was calculated byintegration of the discharge current as a function of time over thedischarge period.

The discharge capacity as a function of the number of cycles is shown inFIG. 2. It will be noted that the cell initially exhibited a maximumcapacity retention of 83% at 49 cycles (ignoring brief excursions abovethis value at cycles 37 and 98-102) and still had an average of 55%discharge capacity at 350 cycles. This represents some shape changeresulting in the effective loss of discharge capacity of 34% compared tothe initial maximum capacity retention.

Prior art cells with zinc active masses formed from either ZnO orZn(OH)₂ and with otherwise identical construction and electrolytecomposition fail due to dendrite growth within 30 cycles under thesecharge/discharge conditions. Furthermore, gross shape change is evidentwith relocation and redistribution of zinc active mass throughout theelectrochemical cell. No gross shape change was evident in thiselectrochemical cell.

EXAMPLE 2

A 1.0 ampere hour cell was constructed of two zinc electrodes and onenickel electrode as shown in FIG. 1. The zinc electrodes had dimensions92 mm (width)×64 mm (height)×2 mm (thickness) and the nickel electrodehad dimensions 87 mm (width)×59 mm (height)×2 mm (width). The nickelelectrode was sandwiched between the two zinc electrodes. The electrodeassembly was mounted in a planar manner within a cell container.

The nickel electrode was prepared by pasting a mixture of nickel (II)hydroxide, graphite and cobalt (II) sulfate onto a metallic spongenickel current collector. An external nickel foil conducting terminalwas spot welded onto the sponge nickel. The active mass was prepared bythorough dry mixing of nickel (II) hydroxide (0.2 mol) and graphite (6g) followed by the addition of water (20 mL) and cobalt (II) sulfate(0.02 mol) followed by further mixing. Finally, potassium hydroxide(0.04 mol) was added to this slurry with mixing and excess water removedby suction. Sufficient paste was applied to the current collector sothat 0.12 mol of nickel (II) hydroxide was present on the nickelelectrode.

The zinc electrodes were prepared from an active composition containinga calcium stearate:zinc hydroxide molar ratio of 0.0527:1 mixed withcarbon powder (19% by weight in the final active mass). The active masswas prepared as an intimate mixture by the two sequential precipitationprocesses described in Example 1. Conditions were identical to thatdescribed in Example 1 with the following alterations: In the firstprecipitation process for Example 2, a suspension of graphite (3 g) andzinc hydroxide (0.1 mol) was prepared and then mixed with potassiumstearate (0.01054 mol). In the second precipitation process, an aqueoussolution of calcium nitrate (5.27×10⁻³ mol) was added to the suspensionof graphite and zinc hydroxide to precipitate the active mass as anintimate mixture of calcium stearate, zinc hydroxide and graphite.

Solid potassium hydroxide (0.3 g) was intimately mixed (by grinding)with the active mass to facilitate the pasting of the active mass ontothe current collectors.

The zinc electrode current collectors were assembled by spot weldingtogether three layers of 40×40 brass mesh. External electrical contactswere made by spot welding nickel foil onto the brass mesh. The nickelfoil was coated with epoxy resin glue to prevent exposure to theelectrolyte.

Sufficient paste was prepared so that each zinc electrode containedactive mass equivalent to 0.1 mol of zinc hydroxide.

Each nickel and zinc electrode was individually enclosed with two layersof woven nylon cloth heat sealed at the bottom, side and top edges (withthe exception of a small opening for the protrusion of the nickel foilelectrical contact). The enclosed nickel electrode was placed betweenthe two enclosed zinc electrodes, which were then wound with nylonthread to ensure the edges of the electrodes remained in close contact.The wound electrode assembly was then enclosed with a shrink-wrappedpolyethylene film sealed at the bottom and side edges but open along thetop edge. Two layers of 60×60 nylon mesh were placed on the outer faceof one side of the electrode assembly to ensure an even pressure acrossthe electrode assembly when the Perspex case was assembled underpressure. The cell was orientated in the vertical configuration.

The electrolyte was 7 M KOH saturated with tetrabutylammonium hydroxideand saturated with ZnO.

In the schematic diagram of the cell shown in FIG. 1, the cell includesa battery case 1, negative electrode connector 2, positive electrodeconnector 3, negative plate internal connecting strap 4, negativeelectrode plate 5, positive electrode plate 6 and separators 7. Theclose-fitting polyethylene bag is not shown.

The cell was subjected to two formation cycles each consisting ofcharging at 160 mA for 10 hours, 5 minutes at open circuit, dischargingat 160 mA until the cell voltage dropped to 1.3 V, followed by 5 minutesat open circuit.

The cell was then cycled through charge and discharge modes. Chargingwas maintained at a current of 500 mA for 2 hours. Upon completion ofcharge the cell was held at open circuit for 5 minutes. Discharge wasmaintained at a constant current of 600 mA until the cell voltagedropped to 1.3 V, indicating full discharge of the cell. Upon completionof discharge the cell was held at open circuit for 5 minutes.

The discharge capacity as a function of the number of cycles is shown inFIG. 3. It will be noted that the cell containing the novel zinc activemass maintained a discharge capacity in excess of 80% for 1134 cycles.During the first 500 cycles the capacity was maintained at better than95% with small cycle-to-cycle variation.

From the 500^(th) to 700^(th) cycles there is a gradual decline from 95%capacity to 89% capacity. This demonstrates that the modified zincelectrode embodied in this patent does not suffer from significant shapechange or dendrite growth.

No gross shape change was evident in the electrochemical cell.

Furthermore, the small decline in capacity over the first 700 cyclesevident in the cell containing the novel zinc active mass can berecovered by controlled and deliberate external electrical shorting ofthe cell for a period of time. In this way, after 720 completecharge/discharge cycles (i.e. terminating on the 5 minute post-dischargeopen circuit period) of the cell containing the novel zinc active mass,the cell was electrically discharged with an external conducting wirefor a period of 24 hours. Following this, and after 3 normalcharge/discharge cycles (not shown in FIG. 2), the cell had recovered to90% capacity. This improvement in capacity continued with cycling sothat after a further 10 cycles (cycle 731), the cell capacity returnedto the 95% capacity shown over the first 500 cycles. This post-shortingrecovery was maintained for a further 140 cycles with littlecycle-to-cycle variation in capacity. After cycle 875 a progressivedecline in capacity was observed so that by completion of 1027 cyclesthe capacity was 88% and in excess of the 80% capacity required forsatisfactory performance. Upon completion of cycle 1134 the capacity haddeclined to the 80% capacity criteria.

It is assumed that use of the combination of zinc stearate and zinchydroxide or of calcium stearate and zinc hydroxide in the active massdecreases the solubility of the zinc electrode discharge productswithout significantly lowering the discharge or charge rate. Withoutwishing to be bound by any theory, it is believed that this decrease inthe solubility of the zinc electrode discharge products decreases thesusceptibility of the zinc electrode to shape change and dendriteformation.

EXAMPLE 3

An electrolyte of 7M KOH saturated with ZnO can be prepared as anelectrolyte that is super-saturated with ZnO by the following method.The zinc content of each solution was determined using atomic absorptionspectroscopy (AAS).

Excess solid ZnO powder was stirred in 30 wt % of KOH solution in 200 mlcovered plastic beakers for 24 hours one maintained at 27° C. and one at97° C. The resulting solution was filtered and the solubility of ZnOdetermined by AAS. At 27° C. the solubility of ZnO was found to be 47.0g/L. At 97° C. the solubility of ZnO was found to be 36.6 g/L.

Excess zinc powder in contact with sponge nickel (JJJ Battery Co. Ltd.,Jiangmen, Guangdong Province, P. R. China) was added to the filteredsolutions of ZnO. The mixtures were then stirred at their originalincubation temperature for 24 hours until a white coating was observedon the surface of the zinc powder and the evolution of hydrogen ceased.

The concentration of ZnO in each solution was determined by AAS. Withrespect to ZnO a concentration of 60.0 g/L was obtained at 27° C. and aconcentration of 54.7 g/L was obtained at 97° C. The solutions areconsidered to be super-saturated with respect to ZnO.

Although the invention has been described with reference to particularembodiments, those persons skilled in the art will appreciate thatvariations and modifications may be made without departing from thescope of the invention.

INDUSTRIAL APPLICATION

It will be appreciated from the discussion above that the presentinvention provides a zinc electrode for use in a rechargeableelectrochemical cell.

Advantageously, rechargeable electrochemical cells incorporating theelectrodes of the invention may be repeatedly charged and dischargedwithout rapid failure due to shape change or dendrite formation. Theelectrochemical cells may be used in portable devices or in fixed energystorage applications.

REFERENCES

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1. A composition for use in preparing a zinc electrode including: (a) Asource of zinc capable of existing in an oxidized and a reduced state;and (b) At least one compound selected from the group consisting ofC₆-C₃₀ fatty acids, salts, esters and other derivatives thereof, andC₆-C₃₀ alkyl sulfonic acids salts, esters and other derivatives thereof.2. A composition as claimed in claim 1 wherein the source of zinc iszinc metal, a zinc salt, zinc oxide, zinc hydroxide, or a mixturethereof.
 3. A composition as claimed in claim 1 wherein the source ofzinc is in an oxidized state.
 4. A composition as claimed in claim 1wherein the source of zinc is a zinc salt, zinc oxide, zinc hydroxide,or a mixture thereof.
 5. A composition as claimed in claim 1 wherein thecompound is a C₆-C₃₀ fatty acid, salt, ester, or other derivativethereof.
 6. A composition as claimed in claim 1 wherein the compound isa naturally occurring C₁₂-C₂₂ fatty acid, salt, ester or otherderivative thereof.
 7. A composition as claimed in claim 1 wherein thecompound is a naturally occurring C₁₆-C₂₀ fatty acid, salt, ester orother derivative thereof.
 8. A composition as claimed in claim 1 whereinthe compound is a metal salt of stearate.
 9. A composition as claimed inclaim 1 wherein the compound is zinc stearate or calcium stearate.
 10. Acomposition as claimed in claim 1 wherein the compound is zinc stearate.11. A composition as claimed in claim 3 wherein the molar ratio of thecompound to the zinc existing in an oxidized state is in the range0.0001:1.0000 to 0.5:1.0.
 12. A composition as claimed in claim 11wherein the range is 0.05:1.00 to 0.4:1.0.
 13. A composition as claimedin claim 11 wherein the range is 0.075:1.000 to 0.25:1.00.
 14. Acomposition as claimed in claim 1 wherein the compound is zinc stearateand the source of zinc is zinc oxide and/or zinc hydroxide.
 15. Acomposition as claimed in claim 14 wherein the molar ratio of zincstearate to the source of zinc is in the range 0.0001:1 to 0.5:1.
 16. Acomposition as claimed in claim 14 wherein the range is 0.05:1 to 0.4:1.17. A composition as claimed in claim 14 wherein the range is 0.075:1 to0.25:1.
 18. A composition as claimed in claim 1 wherein the compound iscalcium stearate and the source of zinc is zinc oxide and/or zinchydroxide.
 19. A composition as claimed in claim 18 wherein the molarratio of calcium stearate to the source of zinc is in the range 0.0001:1to 0.2:1.
 20. A composition as claimed in claim 18 wherein the range is0.01:1 to 0.1:1.
 21. A composition as claimed in claim 18 wherein therange is 0.03:1 to 0.15:1.
 22. A composition as claimed in claim 1wherein the source of zinc and the compound are in admixture.
 23. Acomposition as claimed in claim 22 wherein the source of zinc and thecompound intimately mixed in the admixture.
 24. A composition as claimedin claim 22 wherein the admixture is formed by precipitation.
 25. Amethod of preparing a composition for use in preparing a zinc electrodeincluding the steps of:
 1. Preparing a first precipitate of zinchydroxide;
 2. Mixing a solution of an alkali salt of either a C₆-C₃₀fatty acid or a C₆-C₃₀ alkyl sulfonic acid with a suspension of thefirst precipitate; and
 3. Adding a solution of a salt of a mineral acidto the mix to provide the composition as a second precipitate; whereinthe composition is a mixture of zinc oxide and/or zinc hydroxide, and aninsoluble salt of either a C₆-C₃₀ fatty acid or a C₆-C₃₀ alkyl sulfonicacid.
 26. A method as claimed in claim 25 wherein the first precipitateincludes graphite.
 27. A method as claimed in claim 25 wherein thesolution of an alkali salt of either a C₆-C₃₀ fatty acid or a C₆-C₃₀alkyl sulfonic acid is saturated with zinc.
 28. A method as claimed inclaim 25 wherein the alkali salt of either a C₆-C₃₀ fatty acid or aC₆-C₃₀ alkyl sulfonic acid is an alkali salt of a naturally occurringC₁₂-C₂₂ fatty acid.
 29. A method as claimed in claim 25 wherein thealkali salt of either a C₆-C₃₀ fatty acid or a C₆-C₃₀ alkyl sulfonicacid is an alkali metal salt of stearate.
 30. A method as claimed inclaim 25 wherein the alkali salt of either a C₆-C₃₀ fatty acid or aC₆-C₃₀ alkyl sulfonic acid is potassium stearate.
 31. A method asclaimed in claim 30 wherein the salt of a mineral acid is zinc sulphate.32. A method as claimed in claim 30 wherein the composition is a mixtureof zinc oxide and/or zinc hydroxide, and zinc stearate.
 33. A method asclaimed in claim 32 wherein the molar ratio of zinc stearate to zincoxide and/or zinc hydroxide is in the range 0.0001:1 to 0.5:1.
 34. Amethod as claimed in claim 32 wherein the range is 0.05:1 to 0.4:1. 35.A method as claimed in claim 32 wherein the range is 0.075:1 to 0.25:1.36. A method as claimed in claim 32 wherein the salt of a mineral acidis calcium nitrate.
 37. A method as claimed in claim 36 wherein thecomposition is a mixture of zinc oxide and/or zinc hydroxide, andcalcium stearate.
 38. A method as claimed in claim 37 wherein the molarratio of calcium stearate to zinc oxide and/or zinc hydroxide is in therange 0.0001:1 to 0.2:1.
 39. A method as claimed in claim 37 wherein therange is 0.01:1 to 0.1:1.
 40. A method as claimed in claim 37 whereinthe range is 0.03:1 to 0.15:1.
 41. A composition prepared by a method asclaimed in claim
 25. 42. An electrode comprising a composition asclaimed in claim
 1. 43. An electrode comprising a composition as claimedin claim
 41. 44. An electrode as claimed in claim 42 wherein thecomposition further comprises an alkali metal hydroxide.
 45. Anelectrode as claimed in claim 44 wherein the alkali metal hydroxide ispresent in an amount no less than 0.3 g per 0.1 mole zincoxide/hydroxide.
 46. An electrode as claimed in claim 44 wherein thealkali metal hydroxide is potassium hydroxide.
 47. An electrode preparedfrom a composition as claimed in claim 1 wherein the electrode ischarged.
 48. An electrode prepared from a composition as claimed inclaim 41 wherein the electrode is charged.
 49. A composition preparedfrom an electrode as claimed in claim
 47. 50. A composition preparedfrom an electrode as claimed in claim
 48. 51. A method of preparing anelectrode including the steps of:
 1. Mixing solid alkali metal hydroxidewith a composition as claimed in claim 1;
 2. Applying the mix on to acurrent collector; and
 3. Forming the electrode.
 52. A method as claimedin claim 51 wherein the current collector is woven graphite cloth platedwith metallic tin.
 53. A method as claimed in claim 51 wherein thecurrent collector is brass mesh.
 54. A method as claimed in claim 51wherein the forming the electrode is by applying pressure.
 55. A methodof preparing an electrode including the steps of:
 1. Mixing solid alkalimetal hydroxide with a composition as claimed in claim 41;
 2. Applyingthe mix on to a current collector; and
 3. Forming the electrode.
 56. Amethod as claimed in claim 55 wherein the current collector is wovengraphite cloth plated with metallic tin.
 57. A method as claimed inclaim 55 wherein the current collector is brass mesh.
 58. A method asclaimed in claim 55 wherein the forming the electrode is by applyingpressure.
 59. A cell comprising at least one electrode as claimed inclaim
 42. 60. A cell as claimed in claim 59 wherein the electrode is ananode.
 61. A cell as claimed in claim 59 further comprising anelectrolyte.
 62. A cell as claimed in claim 59 wherein the cell is analkaline cell.
 63. A cell as claimed in claim 59 further comprising aporous separator located between the electrode and at least one otherelectrode.
 64. A cell as claimed in claim 63 wherein the separator is aporous separator.
 65. A cell as claimed in claim 63 wherein the porousseparator is a woven cloth.
 66. A cell as claimed in claim 63 whereinthe porous separator is woven nylon cloth.
 67. A cell as claimed inclaim 61 wherein the electrolyte is saturated with zinc oxide.
 68. Acell as claimed in claim 67 wherein the electrolyte is super-saturated.69. A cell as claimed in claim 61 wherein the electrolyte is saturatedwith tetraalkylammonium salt.
 70. A cell as claimed in claim 61 whereinthe electrolyte is saturated with tetrabutylammonium salt.
 71. A cell asclaimed in claim 61 wherein the accessibility of the electrolyte to theelectrode is restricted.
 72. A cell as claimed in claim 61 wherein theelectrode is enclosed to restrict access of the electrolyte.
 73. A cellas claimed in claim 61 wherein the electrode is enclosed with nyloncloth.
 74. A cell as claimed in claim 59 wherein the electrode assemblyis enclosed with an inert plastic.
 75. A cell prepared from the cell asclaimed in claim 59 wherein the cell is charged.
 76. A cell as claimedin claim 59 wherein the cell is a rechargeable cell.
 77. A rechargeablecell as claimed in claim 75 wherein the cell maintains greater than 55%capacity after 350 charge/discharge cycles, at charge and dischargerates such that charge and discharge of the battery are complete within2-2.5 hours and 1-1.5 hours, respectively.
 78. A rechargeable cell asclaimed in claim 76 wherein the cell maintains greater than 80% capacityafter 1134 charge/discharge cycles, at charge and discharge rates suchthat charge and discharge of the battery are complete within 2 hours and1.7 hours, respectively.
 79. A method of preparing a rechargeable cellcomprising a zinc electrode wherein; the cell maintains greater than 55%capacity after 350 charge/discharge cycles, at charge and dischargerates such that charge and discharge of the battery are complete within2-2.5 hours and 1-1.5 hours, respectively; or the cell maintains greaterthan 80% capacity after 1134 charge/discharge cycles, at charge anddischarge rates such that charge and discharge of the battery arecomplete within 2 hours and 1.7 hours, respectively; including the stepof incorporating an insoluble salt of either a C₆-C₃₀ fatty acid or aC₆-C₃₀ alkyl sulfonic acid in the zinc electrode.
 80. A method ofpreparing an electrolyte super-saturated with zinc oxide including thestep of adding nickel and an excess of zinc metal to a solution of zincoxide.77.A method as claimed in claim 76 wherein the nickel is added asnickel sponge.
 81. A method as claimed in claim 80 wherein the zincmetal is added as a powder.
 82. A method as claimed in claim 80 whereinthe nickel and zinc metal are in contact.
 83. A method as claimed inclaim 80 wherein the nickel contains a platinum group metal.
 84. Amethod as claimed in claim 80 wherein the nickel contains palladium. 85.A method as claimed in claim 80 wherein the solution of zinc oxide isprepared by adding an excess of zinc oxide to a solution of alkali metalhydroxide.
 86. A method as claimed in claim 80 wherein the electrolytecontains greater than 47 g/L ZnO at 27° C.
 87. An electrolyte preparedby the method as claimed in claim 80.